TM
Contents
Introduction
Summary of Control Points............................... 1
06T Model Number Significance....................... 2
Compressor Physical Dimensions..................... 2
Certification..............................................4
Screw Compressor Size (Displacement)...4
Compressor Mounting..............................4
Oil Type....................................................4
Ambient Conditions..................................5
Installation Environment............................5
Pressure Relief Valve................................5
Discharge Check Valve............................ 5
Compressor Inlet Screens........................5
Service Valves..........................................5
Condenser Pressure Control.................... 5
Operational Envelopes............................. 6
Vapor Temperature Limits........................ 7
Minimum Oil Pressure Differential............. 7
Operating Speed Ranges.........................7
Inverters and Refrigerants........................ 8
Compressor Cycling................................ 8
Mechanical Unloading..............................9
High Discharge Pressure Control............. 9
Low Suction Pressure Cut Out.................9
Volume Index (Vi) Control....................... 9
Reverse Rotation Protection....................10
Mufflers...................................................10
Oil Separator........................................... 11
Piping Configuration................................12
System Oil Charge..................................12
Oil Level Switch...................................... 12
Oil Pressure Protection........................... 13
Oil Solenoids...........................................13
Oil Cooling Systems................................14
Oil Cooler Selection.................................16
Oil Filter...................................................20
Oil Sump Heaters................................... 20
Oil Sight Glass........................................ 20
Oil System Schematics........................... 21
Oil Line Manifold Selection Table.............22
5.1
5.2
5.3
Thermal Protection................................. 25
Screw Compressor Motor Protection......26
Circuit Breaker Tables.............................27
Subcooler Selection................................30
Subcooling Correction............................ 30
Superheat Correction............................. 30
Carlyle Software..................................... 30
General Information................................ 31
Compressor Dimensions........................ 31
Compressor C-Flange............................ 31
Compressor Coupling............................ 31
Overall Dimensions................................. 31
Carlyle Electronic Module....................... 36
Motor Selection...................................... 36
Performance Factors.............................. 37
Section 10 Accessory
Part Numbers............................................... 40
Appendix A LonCEM Electronic
Module
Appendix B Original CEM Electronic
Module
Introduction
This manual is for the application of the Carlyle 06T
semi-hermetic and 05T open drive twin screw compressors. The operational limits, required accessories
and operational guidelines are contained in this manual and must be complied with to stay within the
compressor warranty guidelines.
The Carlyle 06T and 05T screw compressors are
gear-driven twin screw compressors. The gear drive
yields the benefits of light weight and small cubic volume. One of the key features of the Carlyle screw
compressor is that all the semi-hermetic models have
the same physical dimensions and port locations, as
do all the open drive models.
The compressors range between 15 and 75 nominal
horsepower, and are designed for use in commercial
refrigeration, process cooling, environmental chamber, and air conditioning applications.
190F (88C)
80F (27C)
*
**
**
**
*
*
**
**
*
* Standard service valve used on all 33-54 cfm Compressors;
** Larger barstock service valve used on all 65-88 cfm Compressors (shown).
1. R-22
2. R-134a
3. R-404A & R-507
The UL file number is SA4936. CSA file
number is LR29937; CSA report number is
LR29937-579c.
For UL and CSA approvals it is essential that
only listed special purpose circuit breakers or
Furnas 958 series soild state overload relays
be used. (See Section 5.2 and 5.3 for selection
tables). The must trip amp settings should not
exceed 140% of the compressor rated load
amps.
Both UL and CSA approvals have been
obtained for all voltage combinations listed
in Section 5.3. 60 Hz compressors have
been listed.
Model
No.
06T**033
06T**039
06T**044
06T**048
06T**054
06T**065
06T**078
06T**088
06T**108
60 Hz
m3/
min
min
33
0.93
39
1.10
44
1.25
48
1.36
54
1.53
65
1.84
78
2.21
88
2.49
N/A
N/A
ft3/
50 Hz
m3/
min
min
27.5
.78
32.5
.92
36.7
1.04
40.0
1.13
45.0
1.28
54.2
1.53
65.0
1.84
73.3
2.08
90.0
2.56
ft3/
R-134a
Medium
Temp. & A/C
YES
YES
YES
YES
YES
R-22
Medium
POE Oil Type
Low Temp.
Temp.
Castrol SW100
*
NO
YES
CPI Solest BVA 120
*
YES
YES
CPI Solest 170
**
YES**
YES**
ICI Emkarate RL100S
YES
YES
Castrol E100
*
YES
YES
* UL Certified
For application purposes, Solest 120 oil is considered to be the same viscosity as POE 100 oils.
** Required for R-22 systems without external oil Cooler. R-22 systems with external oil cooler may use POE 100 oils.
-40F To 130F
(-40C To 54C)
-40F To 130F
(-40C To 54C)
-25F To 130F
(-32C To 54C)
Connection
Suction
Discharge
Economizer
Connection
Max.
1-5/8"
1-5/8"
7/8"
Size
Min.
1-1/8"
1-1/8"
7/8"
Important!
Large variations in head pressure will
result in very poor oil separation which
may result in nuisance oil level switch
tripping. The condenser pressure must
be controlled such that fluctuations are
gradual. Carlyle screw compressors
must be applied with a minimum of one
condenser fan (preferably variable speed)
active at all times and a means of minimum
head pressure control for low ambient
operation. For alternate methods of condenser control, please contact Carlyle
Application Engineering.
R-22 APPLICATIONS
(60) 140
(49) 120
tro
on
C
mp
e
hT
(38) 100
Oil
C
ling
tro
on
c
Dis
Co
(27) 80
(16) 60
(4) 40
(-7) 20
(-18) 0
-30 -25
-40 -35
(-40) (-37) (-34) (-32)
5
-15 -10
-5
0
-20
10
(-29) (-26) (-23) (-21) (-18) (-15) (-12)
15
(-9)
20
(-7)
25
(-4)
30
(-1)
35
(2)
40
(5)
45
(8)
50
(11)
R-134a APPLICATIONS
Discharge
Temperature
Control and
Oil Cooling
Required
(71) 160
emp
ch T
(60) 140
trol
Con
trol
Dis
Oil
ng
ooli
Con
(49) 120
Oil Cooling
Required
(38) 100
No Oil or Discharge
Control
Requirements
(27) 80
(16) 60
(4) 40
(-7) 20
(-18) 0
-10
(-23)
-5
(-21)
0
(-18)
5
(-15)
10
(-12)
15
(-9)
20
(-7)
25
(-4)
30
(-1)
35
(2)
40
(4)
45
(7)
50
(10)
55
(13)
R-507/R404A APPLICATIONS
APPLICATIONS
R-507-R404A
(60) 140
ol
ntr
(49) 120
o
pC
ch
Dis
m
Te
rol
ont
(38) 100
Oil
C
ling
Coo
(27) 80
(16) 60
(4) 40
(-7) 20
(-18) 0
-50 -45 -40 -35 -30 -25 -20 -15 -10 -5
5
10 15
0
(-46) (-43) (-40) (-37) (-34) (-32) (-29) (-26) (-23) (-21) (-18) (-15) (-12) (-9)
20 25
(-7) (-4)
30
(-1)
35
(2)
Min.
10F SH*
(6C)
Saturated**
Vapor
The operating speed range for the screw compressor is as follows for the different size range
compressors.
Model
No.
06T**033
06T**039
06T**044
06T**048
06T**054
06T**065
06T**078
06T**088
06T**108
Max.
100F
(38C)
NonEconomized
*SH = Superheat
**The maximum economizer pressure allowable is
175.3 psig (13.1 bar)
ft3/
min
33
39
44
48
54
65
78
88
90*
* 50 Hz Applications only.
m3/
min
0.93
1.10
1.26
1.36
1.53
1.84
2.21
2.49
2.56*
Min.
Hz
50
40
35
30
30
25
20
20
20
Max.
Hz
70
70
70
70
70
70
68
60
50
Table 1
Nominal
HP
15
20
20
25
25
30
35
40
50
Min.
Hz
50
40
35
30
30
25
20
20
20
Max.
Hz
70
70
70
70
70
70
68
60
50
Table 2
Nom.
HP
20
25
30
30
35
35
40
50
Min.
Hz
50
40
35
30
30
25
20
20
Max.
Hz
70
70
70
70
70
70
68
60
A high pressure cut out must protect the compressor from exceeding 350 psig (25.2 bar).
The compressor may be brought back on
line after the discharge pressure falls
below 300 psig (21.4 bar). The maximum pressure differential (discharge-suction) is 350 psi.
The internal pressure relief valve will open if the
pressure differential exceeds 400 psi (+/-3%).
ESTIMATED PERCENTAGE
UNLOADING BY MODEL
ft3/
min
33
39
44
48
54
65
78
88
m3/
min
0.93
1.10
1.25
1.36
1.53
1.84
2.21
2.49
Low
Med.
Temp. Temp.
60%
50%
59%
49%
58%
48%
56%
46%
55%
45%
50%
40%
45%
35%
40%
30%
Models
@ 50 Hz
06T**033
06T**039
06T**044
06T**048
06T**054
06T**065
06T**078
06T**088
06T**108
ft3/
min
27.5
32.5
36.7
40.0
45.0
54.2
65.0
73.3
90.0
m3/
min
0.78
0.92
1.04
1.13
1.28
1.53
1.84
2.08
2.56
Low
Med.
Temp. Temp.
62%
52%
61%
51%
60%
50%
59%
49%
58%
48%
55%
45%
50%
40%
47%
37%
46%
-
Models
@ 60 Hz
06T**033
06T**039
06T**044
06T**048
06T**054
06T**065
06T**078
06T**088
(20.7 300
5
(.3)
10
(.7)
15
20
25
35
40
45
50
30
(1.0) (1.4) (1.7) (2.1) (2.4) (2.8) (3.1) (3.4)
Suction Pressure psig (bar)
2.12 Mufflers
Correct compressor rotation is critical for compressor reliability. The compressor can fail within 2-6 seconds of start-up if it is not rotating in
the correct direction. Installation of a pressure
gage at the discharge pressure access fitting in
the compressor body (measuring the pressure
upstream of the integral discharge check valve)
is recommended during initial start-up or
whenever the compressor is serviced. The
gage should be monitored to ensure increasing
discharge pressure at start-up.
FUSE
L2
FUSE
L1
FUSE
LS3
LS2
LOAD
LS1
CHECKS
SOURCE
VOLTAGE
L3
L1
L2
C
CONTROL
VOLTAGE
19-240
VAC/VDC
SYMMETRY
LOCKOUT
MINUTES
FAULT
INTERROGATION
SECONDS
LOAD ENERGIZER
HIGH VOLTAGE
LOW VOLTAGE
LS3
LS2
LS1
VOLTAGE
ADJUST
CHECKS
LOAD
VOLTAGE
10
11
OUTLET
INLET
DEFINITIONS:
OIL_LEVEL
PROGRAM VARIABLE
OIL_LEVEL =1
OIL LEVEL OK
OIL_LEVEL = 0
OIL LEVEL FAULT
FLOAT PROGRAM COUNTER VARIABLE
LEVEL PROGRAM VARIABLE TO INCREMENT/DECREMENT
COUNTER
LEVEL = 1 OIL LEVEL OK
LEVEL = -1 OIL LEVEL FAULT
PROGRAMMING:
INITIALIZATION BLOCK
FLOAT = 3
PROGRAM BLOCK
READ OIL_LEVEL
LEVEL = 2*(OIL_LEVEL - .5)
~CONVERTS 1 OR 0 TO 1 OR -1
FLOAT = FLOAT + LEVEL
IF (FLOAT = 0) THEN SHUTDOWN COMPRESSOR(S)
IF (FLOAT>3) THEN (FLOAT = 3)
~LIMIT FLOAT TO MAXIMUM OF 3
REPEAT PROGRAM BLOCK EACH 15 SECONDS
12
Parameter
Oil system
Pressure
Drop
Oil Pressure
Differential
Explanation
Alarm/Cut-Out
Reset
Discharge pressure
oil pressure is
greater than 35 psi
(2.4bar)
Discharge pressure
oil pressure is
greater than 50 psi
(3.4bar)
Oil pressure
suction pressure is
less than 45 psi
(3.0bar) for 90
seconds or more
Alarm
Auto
Cut-Out
Manual
Cut-Out
Manual
13
Warning!
When testing the control circuit without the
compressor running, the oil line must be valved off
so that the compressor will not be filled with oil.
Whenever possible use control logic to determine that the compressor is actually running
before opening the oil solenoid. There are
two ways to accomplish this:
1. Make sure the current is greater than zero
and less than the locked rotor amperage
(LRA).
2. Make sure the discharge plenum pressure
is greater than the suction pressure (this
method is ineffective on multiple compressor racks).
Saturated Suction:
Saturated Condensing:
Recommended Oils:
-40 F to 0 F
70 F to 120 F
0 F to 50 F
70 F to 130 F
-10 F to 50 F
70 F to 150 F`
-25 F to 0 F
70 F to 120 F
POE 170*
-30 F to -26 F
70 F to 110 F
POE 170*
0 F to 50 F
70 F to 130 F
POE 170*
14
discharge service valve. A properly sized solenoid valve should be located upstream to
insure positive shut-off when the compressor is
off.
The tables presented at the bottom of this
page present desuperheating size and part
number information for those applications
where an oil cooler is not used.
Even when an oil cooler is used, desuperheating may still be required. For R-22 systems,
the desuperheating valve is required when
the saturated suction temperature is below
-25F (-32C) and for R-404A/R-507 systems,
it is necessary when the saturated suction
temperature is below -40F (-32C). This valve
is available through Carlyle (1 ton (3.5Kw);
1.5 ton (5.3Kw); contact Carlyle Application
Engineering for valve selection).
HP
06TRC033
15
06TRD039
20
06TRD044
20
06TRE048
25
06TRE054
25
06TRF065
30
06TRG078
35
06TRH088
40
06TRK108
50
Med Temp/High Temp
SCT Range
06TAD033
06TAE039
06TAF044
06TAF048
06TAG054
06TAG065
06TAH078
06TAK088
20
25
30
30
35
35
40
50
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
70 to 130 F
(21 to 54 C)
FV-2**
FV-3**
FV-3**
FV-3**
FV-3**
FV-5**
FV-5**
FV-5**
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
70 to 150 F
(21 to 65 C)
None
None
None
None
None
None
None
None
None
70 to 150 F
(21 to 65 C)
None
None
None
None
None
None
None
None
None
70 to 130 F
(21 to 34 C)
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
LEGEND
*
Operation with Evap condensers below -25 F SST may not require any additional desuperheating.
Contact Carlyle Applicatioon Engineering for limits.
** Operation with Evap condensers above +10F SST may not require any additional desuperheating.
Contact Carlyle Application Engineering for limits.
Note: Valve P/N's shown above are for Sportan Valve Y-1037 series desuperheating valves. A valve with a 190 F temperature setting is required. Alternate
desuperheating valve sizing or manufacturers must be approved by Carlyle Application Engineering.
Qty./Pkg.
1
1
1
1
1
Weight (Lbs.)
2
2
2
2
2
15
Size
1 ton
1-1/2 ton
2 ton
3 ton
5 ton
95F
(35C)
32,100 Btu/Hr
(9,405 W/Hr)
69,100 Btu/Hr
(20,246 W/H)
102,600 Btu/Hr
(30,061 W/Hr)
134,100 Btu/Hr
(39,291 W/Hr)
95F
(35C)
32,200 Btu/Hr
(9,405 W/Hr)
63,700 Btu/Hr
(18,664 W/H)
94,900 Btu/Hr
(27,805 W/Hr)
123,400 Btu/Hr
(26,156 W/Hr)
*Maximum Number of Compressors Based on Oil Cooler Pressure Drop of Less Than 6 PSID (.41 bar)
16
MODEL # KH51ZZ181
17
MODEL # KH51ZZ182
MODEL # KH51ZZ183
18
MODEL # KH51ZZ184
8.25"
(209.6cm)
1.75"
(44.5cm)
1.00"
(25.4cm)
END CAP,
1.75" (44.5cm) O.D. X 1.00" (25.4cm)
I.D. W/ORING GROOVE
3u FIBERGLASS
SUPPORTED
3.25
(82.6)
INLET I.D.
0.876/0.880
(22.23/22.35)
X 0.75 (19.1) DEEP
0.06
5.25
(133.4)
3.25
(82.6)
2 5/16" - 16 UNC
THREADED O-RING
CLOSURE
2.62 O.D.
(66.6)
0.06
10.00
(254.0)
0.06
8.56
(217.4)
DRAIN
1/4"-3000# NPT
HALF COUPLING
(PLUGGED)
FOR REFERENCE ONLY
INCHES
[MILLIMETERS (mm)]
19
FLEX
HEATER
15.75
(400mm)
6.0
(152mm)
REF.
0.175
(4.4mm)
20
+/-.005
FOR REFERENCE ONLY
INCHES
[MILLIMETERS (mm)]
0.050
(1.27mm)
240 V
NATURAL
BLACK
RED
120 V
DISCHARGE
LINE
OIL SEP.
LEAD COMPRESSOR
OIL HEATER
OIL LEVEL SWITCH
3 MICRON FILTERS
IL
LI
OIL COOLER
(IF REQUIRED)
MIXING
VALVE*
*
PRESSURE SENSOR
OIL SOLENOID
HAND VALVE
SIGHT GLASS
* Note: Other oil temperature control options are available. See section 3.8.
21
Manifold
O.D. (in.)
7/8
7/8
7/8
1-1/8
1-1/8
at 10 cSt
0.17
0.34
0.52
0.22
0.27
Delta P (PSI)
at 45 cSt
at 100 cSt
0.77
1.72
1.54
3.43
2.31
5.15
0.97
2.16
1.21
2.69
at 170 cSt
2.92
5.83
8.76*
3.67
4.58
20 Ft Manifold Length
Assumed
Number of
Compressors
GPM
LPM
1
2
7.6
2
4
15.2
3
6
22.8
4
8
30.4
5
10
38
Manifold
O.D. (in.)
7/8
1-1/8
1-1/8
1-1/8
1-1/8
at 10 cSt
0.34
0.22
0.32
0.43
0.54
Delta P (PSI)
at 45 cSt
at 100 cSt
1.54
3.43
0.97
2.16
1.46
3.24
1.94
4.31
2.43
5.39
at 170 cSt
5.84
3.67*
5.50
7.33
9.17*
30 Ft Manifold Length
Assumed
Number of
Compressors
GPM
LPM
1
2
7.6
2
4
15.2
3
6
22.8
4
8
30.4
5
10
38
Manifold
O.D. (in.)
1-1/8
1-1/8
1-1/8
1-1/8
1-3/8
at 10 cSt
0.15
0.32
0.49
0.65
0.33
Delta P (PSI)
at 45 cSt
at 100 cSt
0.70
1.62
1.45
3.24
2.18
4.85
2.91
6.47
1.49
3.30
at 170 cSt
2.75*
5.50
8.25*
11.00*
5.61
40 Ft Manifold Length
Assumed
Number of
Compressors
GPM
LPM
1
2
7.6
2
4
15.2
3
6
22.8
4
8
30.4
5
10
38
Manifold
O.D. (in.)
1-1/8
1-1/8
1-1/8
1-1/8
1-3/8
at 10 cSt
0.25
0.43
0.65
0.35
0.44
Delta P (PSI)
at 45 cSt
at 100 cSt
0.91
2.42
1.94
4.32
2.91
6.47
1.50
3.52
1.98
4.40
at 170 cSt
3.67*
7.34*
11.00*
5.99
7.48*
Number of
Compressors
1
2
3
4
5
LEGEND
LPM - Litres per minute
cSt - Centistrokes
* If 170 POE oil is used, Carlyle recommends use of the next larger size copper line if pressure drop is greater
than 5.0 psi. This will typically reduce pressure drop to 30% of value shown.
NOTES:
1. Viscosity of 10 cSt is based on 130 F (54 C) oil with 10% refrigerant dilution.
2. Viscosity of 45 cSt is based on 130 F (54 C) oil, no refrigerant dilution or 80 F (27 C) oil
with 10% refrigerant dilution.
3. Viscosity of 100 cSt is based on 100 F (38 C) oil, no refrigerant dilution.
4. Viscosity of 170 cSt is based on 100 F (38 C) oil, with no refrigerant dilution.
22
EVAPORATOR
CONDENSER
LEAD COMPRESSOR
LPS
OIL SEP.
HPS
LPS
HPS
DISCHARGE
LPS
HPS
LPS
HPS
HPS
HIGH PRESSURE
SWITCH
EXPANSION VALVE
LPS
LOW PRESSURE
SWITCH
SOLENOID
MOTOR COOLING
VALVE
CHECK VALVE
23
ECONOMIZER
EVAPORATOR
CONDENSER
LEAD COMPRESSOR
LPS
OIL SEP.
LPS
HPS
LPS
HPS
DISCHARGE
HPS
LPS
24
HPS
may be measured at the module while the compressor is running and compared to the Temperature vs.
DC voltage table. (WARNING: DO NOT MEASURE
THE DC VOLTAGE INSIDE THE TERMINAL
BOX.)
Note that while the resistance of the sensors does
not change, the measured DC voltage will be different depending on which protection module is used.
See the "Motor and Discharge Thermistors" table in
Appendix A for the conversion when using the newer
LonCEM module, and the "Temperature VS. DC
Voltage" table in Appendix B for older applications
with the CEM module.
C
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
F
32
33.8
35.6
37.4
39.2
41
42.8
44.6
46.4
48.2
50
51.8
53.6
55.4
57.2
59
60.8
62.6
64.4
66.2
68
69.8
71.6
73.4
75.2
77
78.8
80.6
82.4
84.2
86
87.8
89.6
91.4
93.2
95
96.8
98.6
RESISTANCE
OHMS
16352.4
15515.2
14750
14027.1
13343.8
12697.8
12086.3
11508
10960.8
10442.6
9951.8
9486.8
9046.3
8628.7
8232.5
7857
7500.6
7162.3
6841.3
6526.4
6246.8
5971.6
5710
5461.3
5225
5000
4786
4582.4
4388.5
4203.9
4028
3860.5
3700.8
3548.5
3403.5
3265.1
3133.1
3007.1
TEMPERATURE
C
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
F
100.4
102.2
104
105.8
107.6
109.4
111.2
113
114.8
116.5
118.4
120.2
122
123.8
125.6
127.4
129.2
131
132.8
134.6
136.4
138.2
140
141.8
143.6
145.4
147.2
149
150.8
152.6
154.4
156.2
158
159.8
161.6
163.4
165.2
167
RESISTANCE
OHMS
2886.9
2772.1
2662.4
2557.8
2457.7
2362.1
2270.8
2183.45
2099.93
2020.04
1943.6
1870.5
1800.49
1733.46
1669.66
1607.81
1548.95
1492.54
1438.46
1386.62
1336.93
1289.26
1243.53
1199.7
1157.59
1117.18
1078.37
1041.15
1005.38
971.03
938.02
906.3
875.81
846.5
818.31
791.21
765.14
740.06
25
TEMPERATURE
C
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
F
168.8
170.6
172.4
174.2
176
177.8
179.6
181.4
183.2
185
186.8
188.6
190.4
192.2
194
195.8
197.6
199.4
201.2
203
204.8
206.6
208.4
210.2
212
213.8
215.6
217.4
219.2
221
222.8
224.6
226.4
228.2
230
231.8
233.6
235.4
RESISTANCE
OHMS
715.93
692.68
670.34
648.82
628.09
608.11
588.88
570.36
552.5
535.29
518.7
502.7
487.28
474.4
458.06
444.2
430.85
417.96
405.51
393.49
381.89
370.69
359.87
349.41
339.32
329.55
320.12
311
302.18
293.65
285.41
277.43
269.72
262.26
255.03
248.04
241.28
234.72
TEMPERATURE
C
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
F
237.2
239
240.8
242.6
244.4
246.2
248
249.8
251.6
253.4
255.2
257
258.8
260.6
262.4
264.2
266
267.8
269.6
271.4
273.2
275
276.8
278.6
280.4
282.2
284
285.8
287.6
289.4
291.2
293
294.8
296.6
298.4
300.2
302
RESISTANCE
OHMS
228.38
222.24
216.29
210.53
204.95
199.54
194.3
189.22
184.3
178.5
174.89
170.41
166.06
161.83
157.74
153.77
149.91
146.17
142.54
139.02
136.6
132.27
129.04
125.91
122.87
119.91
117.04
114.25
111.54
108.9
106.34
103.86
101.43
99.074
95.785
94.559
92.393
26
ALLOWABLE OPERATING
VOLTAGE RANGES
Name Plate Frequency Min.
Max.
Voltage
(Hz)
Voltage Voltage
208230
60
187
264
200
50
180
230
230
50
198
264
460
60
396
528
400
50
342
456
575
60
495
660
400
60
342
460
27
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
400-3-50
06TRC033C
06TRC033B
06TRC033F
06TRD039C
06TRD039B
06TRD039F
06TRD044C
06TRD044B
06TRD044F
06TRE048C
06TRE048B
06TRE048F
06TRE054C
06TRE054B
06TRE054F
06TRF065C
06TRF065B
06TRF065F
06TRG078C
06TRG078B
06TRG078F
06TRH088C
06TRH088B
06TRH088F
06TRK108B
50
40
35
30
25
25
20
20
15
HP
33.5
46
90
39
49
104
39
49
104
53
64
128
53
64
128
62
76
154
72
89
181
81
101
203
114
MAX MTA
(See Note #1)
CIRCUIT BREAKER
PART #
HH83XA460
HH83XA463
HH83XB626
HH83XA461
HH83XA424
HH83XB625
HH83XA461
HH83XA424
HH83XB625
HH83XA469
HH83XA426
HH83XC509
HH83XA469
HH83XA426
HH83XC509
HH83XB617
HH83XA474
HH83XC573
HH83XB618
HH83XA475
HH83XC574
HH83XB619
HH83XA476
HH83XC575
HH83XA477
LRA
XL
114
142
286
138
173
348
138
173
348
172
215
433
172
215
433
219
253
611
258
323
721
296
370
825
440
RLA
(See Note 3)
23.2
32
64
27.2
34.4
73.6
27.2
34.4
73.6
35.2
44.8
91.2
35.2
44.8
91.2
44
52.8
108.8
51.2
62.4
128
57.6
72
144
80
MTA
32.5
44.8
89.6
38.1
48.2
103
38.1
48.2
103
49.3
62.7
127.7
49.3
62.7
127.7
61.6
73.9
152.3
71.7
87.4
179.2
80.6
100.8
201.6
112
LEGEND
RLA=Rated Load Amps
PW=Part-Winding Start
LRA=Locked Rotor Amps
MH=Must Hold Amps
XL=Across-the-Line Start
MTA=Must Trip Amps
NOTES:
1. Compressor must trip amps are maximum figures. Overcurrent protection must trip at or below this value.
2. LRA value for PW 2nd winding = 1/2 the LRA XL value.
3. Recommended RLA value = Crt Brk must trip value / 1.4. Use this recommended RLA value to determine minimum contactor sizing and wiring sizing. See also detail on Compressor Amperage
Ratings on Unit Rating Plate.
4. Alternate over current protection device which can be used in place of calibrated circuit breaker.
5. Carlyle 06TR 400-3-50 units have the same circuit breaker table ratings as 460-3-60. Refer to 460-3-60 data for 50Hz information.
VOLTAGE
COMPRESSOR
MODEL
28
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
575
400/460
208/230
VOLTAGE
50
40
35
35
30
30
25
20
HP
39
49
104
53
64
128
62
76
163
62
76
163
78
88
182
72
89
181
81
101
203
92
114
230
MAX MTA
(See Note #1)
CIRCUIT BREAKER
PART #
HH83XA461
HH83XA424
HH83XB625
HH83XA469
HH83XA426
HH83XC509
HH83XA430
HH83XA478
HH83XC539
HH83XA430
HH83XA478
HH83XC539
HH83XA453
HH83XA547
HH83XC532
HH83XB618
HH83XA475
HH83XC574
HH83XB619
HH83XA476
HH83XC575
HH83XB610
HH83XA477
HH83XC576
LRA
XL
138
173
348
172
215
433
202
253
510
202
253
510
242
305
610
258
323
721
296
370
825
351
440
974
RLA
(See Note 3)
27.2
34.4
73.6
35.2
44.8
91.2
41.6
52
115.2
41.6
52
115.2
55.2
62.4
129.6
55.2
62.4
128.8
57.6
72
144
62.4
80
160
MTA
38.1
48.2
103
49.3
62.7
127.7
58.2
72.8
161.3
58.2
72.8
161.3
77.3
87.4
181.4
77.3
87.4
180.3
80.6
100.8
201.6
87.4
112
112
LEGEND
RLA=Rated Load Amps
PW=Part-Winding Start
LRA=Locked Rotor Amps
MH=Must Hold Amps
XL=Across-the-Line Start
MTA=Must Trip Amps
* To use Furnas overload w/06TAK088F2EA-A00, compressor must be wired for part-winding start and 2 overloads wired in parallel with
2 contactors. Furnas must hold setting = 100. MTA Setting = 112.
NOTES:
1. Compressor must trip amps are maximum figures. Overcurrent protection must trip at or below this value.
2. LRA value for PW 2nd winding = 1/2 the LRA XL value.
3. Recommended RLA value = Crt Brk must trip value / 1.4. Use this recommended RLA value to determine minimum contactor sizing and wiring sizing. See also detail on Compressor Amperage
Ratings on Unit Rating Plate.
4. Alternate over current protection device which can be used in place of calibrated circuit breaker.
5. Carlyle 06TA 400-3-50 units have the same circuit breaker table ratings as 460-3-60. Refer to 460-3-60 data for 50Hz information.
06TAD033C
06TAD033B
06TAD033F
06TAE039C
06TAE039B
06TAE039F
06TAF044C
06TAF044B
06TAF044F
06TAF048C
06TAF048B
06TAF048F
06TAG054C
06TAG054B
06TAG054F
06TAG065C
06TAG065B
06TAG065F
06TAH078C
06TAH078B
06TAH078F
06TAK088C
06TAK088B
06TAK088F*
COMPRESSOR
MODEL
2.50
(63.5)
0.50
(12.7)
NO BENDS WITHIN
1.50" OF HEAD
(38.1)
3.89
(98.8)
INLET
OUTLET
1.37
(34.8)
0.94
(23.9)
HEX
1.33
(33.8)
MAIN LIQUID
VAPOR OUT
TO COMPRESSOR
ECONOMIZER PORT
0.3775/0.3805 DIA.
(9.588/9.665)
TYP. (INLET & OUTLET)
EACH CONNECTION
0.31
(7.9)
MIN.
0.31
(7.9)
MIN.
1.78
(45.2)
1.69
(42.9)
29
METHOD 1
Vary compressor capacity by 3% for each
10F (6C) difference between actual and
rated liquid temperature. For example, if the
actual liquid temperature was 50F (10C)
and the rated liquid temperature was 40F
(5C), divide the rated capacity by 1.03.
This method is specifically for R-22.
METHOD 2
Using the mass flow rates published in the
rating tables, a thermodynamic correction
may be used by calculating the new change
in enthalpy across the evaporator and multiplying it by the evaporator mass flow rate.
30
The 05T compressor is a compact and lightweight open drive screw compressor which
delivers high capacity for its size. It is very similar to the 06T semi-hermetic screw compressor. With the exception of an internal motor,
the 05T and 06T are virtually identical. In place
of the internal motor, the open drive is supplied
with a gear casing and jack shaft to connect
an external C-Face motor or other device. The
compression end of the compressor is identical
to the 06T semi-hermetic screw compressor.
5.72"
(145.3mm)
15.13"
(384.3mm)
.59"
(15.0mm)
22.00"
(558.9mm)
06T
Model #
06T**033
06T**039
06T**044
06T**048
06T**054
06T**065
06T**078
06T**088
05T
Model #
RPM
Ft3/min m3/min
60Hz (50Hz) @ 60Hz @ 50Hz
33
39
44
48
54
65
78
88
.78
.92
1.04
1.13
1.28
1.53
1.84
2.08
14.15"
(359.4mm)
2.77"
(70.3mm)
2.13"
(54.2mm)
5.83"
(148.1mm)
4.00"
(101.8mm)
.59"
(15mm)
.59"
(2X 15mm)
11.81"
(300.0mm)
31
5.28"
(134.0mm)
Motor
Selection
15Hp (254TC)
5.92"
(150.5mm)
Speed
C-Flange
Package
Required
Dimensions
0TA0929
C-flange
drawing A
0TA0930
C-flange
drawing B
0TA0931
C-flange
drawing C
12.14"
(308.4mm)
60Hp (364TSC)
75Hp (365TSC)
2.08"
(52.9mm)
3.82"
(97.0mm)
4.76"
(121.0mm)
6.46"
(164.1mm)
32
+.0005
2X .500
(77.5)
D
1
3.05
X .63 DEEP
0
.0015
(295.3)
11.625"
-C-
-D-
-A-
45
4X 17/32 THRU
.015 M
-Z-
B S D
(132.3) 5.21
R5 .39
(136.9)
12.50" (317.5)
90
(132.3) 5.21
-B-
5.00
(127)
R .25
(6.4)
3.05
(77.5)
D
2
1.0"
(25.4)
1.13
(28.7)
(77.5)
D
1
+.0005
2X .500 0
X .63 DEEP
.539 X 90 CSK
.0015 S C
3.05
B S
(273.1)
10.750"
-C-
-D-
-A-
45
4X 17/32 THRU
M
.015
B S D
(132.3) 5.21
R5 .39
(136.9)
10.50" (266.7)
90
-B-
5.00
(127)
(132.3) 5.21
3.05
(77.5)
D
2
R . 25
(6.4)
1.13
(28.7)
1.0"
(25.4)
FOR REFERENCE ONLY
INCHES
[MILLIMETERS (mm)]
+.0005
X .63 DEEP
0
2X .500
(77.5)
D
1
3.05
.0015
-C-
-D-
45
4X 17/32 THRU
.015 M C
-Z-
(250.8)
9.875"
-A-
(132.3) 5.21
R5 .39
12.50" (317.5)
90
(132.3) 5.21
-B-
5.00
3.05
(77.5)
D
2
R .25
(6.4)
1.13
(28.7)
1.0"
(25.4)
33
Motor
Selection
Speed
15Hp (254TC)
20Hp (256TC)
25Hp (284TC)
30Hp (286TC)
40Hp (324TC)
50Hp (326TC)
30Hp (286TSC)
Motor
Shaft
Dia.
(Inch)
Coupling
Package
Required
1-5/8
8TA0868B
1-7/8
8TA0869B
2-1/8
8TA0870B
1-5/8
8TA0868B
1-7/8
8TA0869B
40Hp (324TSC)
50Hp (326TSC) 3500 rpm @ 60Hz
60Hp (364TSC) 2900 rpm @ 50Hz
75Hp (365TSC)
Table 8-3
5.45"
(138.4 mm)
4.44"
(112.8 mm)
Coupling Dimensions
34
All the 05T compressors have the same external physical dimensions, therefore the variables
that will affect the overall dimensions of the
assembly are the motor and C-Flange. The
dimensional drawing shown in the 05T dimension drawing supplies the assembly dimensions with the different C-Flanges and motors.
C-Flange
Package
HP
Motor
RPM.
NEMA
Frame
in.
A
cm.
in.
15
1750
254TC
8.25
20.96
5.00
0TA0929 20
1750
25
1750
284TC
30
in.
cm.
.106
.28
.56
1.42
5.00
.106
.28
.56
1.42
24.13
5.50
.858
2.18
.56
1.42
1750
5.50
.858
2.18
.56
1.42
0TA0930 40
1750
6.25
1.86
4.72
.69
1.75
50
1750
6.25
1.86
4.72
.69
1.75
30
3500
5.50
.858
2.18
.56
1.42
40
3500
6.25
1.86
4.72
.69
1.75
0TA0931 50
3500
6.25
1.86
4.72
.69
1.75
60
3500
7.00
2.86
7.26
.69
1.75
75
3500
7.00
2.86
7.26
.69
1.75
05T Dimensions
35
cm.
E
cm.
in.
D
in.
9.50
cm.
36
Motor Speed
Input Shaft
Min.
Max.
05T
60Hz (50Hz) Speed Speed
Model
#CFM
(RPM)
(RPM) (RPM)
33
1750 (1450)
05TRQ033
1450
4000
65
3500 (2900)
39
1750 (1450)
05TRQ039
1167
4000
78
3500 (2900)
44
1750 (1450)
05TRQ044
1020
3600
88
3500 (2900)
05TRQ048 48
1750 (1450)
875
3300
05TRQ054 54
1750 (1450)
875
2930
)(
37
38
Pressure Differential:
5. During compressor operation ensure that the economizer solenoid (if the economizer is used),
liquid injection solenoid and oil line solenoid (taking into account the time delay) are
energized and de-energize on shut down.
6. If an economizer is used, set the superheat leaving the subcooler to 6F to 15F (3C to 9C).
Subcooler Vapor Pressure:
Saturation Temperature:
Superheat:
7. Check the oil temperature entering the compressor and ensure that it is less than 190F (88C).
Oil Temperature:
8. Check functionality of the LonCEM/Carlyle Electronic Module:
Disconnect either 5K thermistor from the LonCEM/CEM to verify that the compressor will not start
and all solenoid valves stay off.
Check to ensure that the motor cooling valve will feed (head pressure may have to be manually
raised).
39
Qty.
1
Qty.
1
1
40
Accessory
Part Number
Circuit Breaker
HH83X . . .
Oil Press. Diff. Sw. HK06ZB006
Older Systems HK06ZB001
1
Rev. Rotation Sw. HK01CB002
Older Systems HK01CB001
1
Muffler
LM10HH162
1
C.E.M.
3TA0796B
1
LonCEM
OTA1063
1
5K Thermistor
HH79NZ065
1
Motor Cool. Valve EF28BZ007
1,2 or 3 Solenoid Coil for:
Unloader, Vi or oil solenoid:
EF19ZE (120,240,024)
For motor cool. valve:
P510-XV (024,120,208) D
05T Open Drive Add
1
C Flange Package 0TA0929
0TA0930
0TA0931
1
Coupling
8TA0868B
8TA0869B
8TA0870B
1
Desuperheating
EA02ZD001- 1 ton,
Valve
002-1.5 ton,
030-2 ton,
050-3 ton,
100-5 ton
1
Motor Cooling Valve EF25BZ007
Each fitting yields (3) 1/4 male flare connections
when installed. One of the connections has a
schrader valve and cap, which is to be used for field
gauge connections. The other two fittings (which do
not have schrader valves) are to be used for the
pressure transducer and the low/high pressure
switch, respectively. See section 3.2 of the LonCEM
Installation instructions (which follows in Appendix A)
for more details on the access ports.
05T CEM
For open drive compressors, the CEM motor cooling
valve output will control a motor cooling valve which
injects liquid directly into the inter-stage service valve
port. A 5K resistor will be required as a jumper in
place of the motor 5K thermistor.
APPENDIX A
05T/06T
Screw Compressor Module
LonCEM
Table of Contents
Page
1.0 Overview
11
12
13
14
15
17
P O Box 4808
Phone: 800-462-2759
Syracuse, NY 13221
Fax: 315-432-3274
1.0
Overview
The LonCEM is a solid state electronic module used as the primary compressor
protection for our 74mm screw compressors. It is used on both our semi-hermetic (06T)
and open-drive (05T) air conditioning and refrigeration compressors. Special
instructions for 05T installations are provided in Section 3.4. The module provides
thermal compressor protection by monitoring motor and discharge temperature and
providing liquid injection cooling as required. Oil pressure protection is provided by
monitoring suction, discharge and oil pressure. Pressure drop through the oil system (oil
filters, oil cooler, oil line solenoid etc.) is continuously monitored to insure proper oil flow.
Other features include reverse rotation protection, 20 second time-delay between
compressor starts, volume index control for refrigeration models, and startup sequencing
of the oil and economizer solenoid valves. A functional overview providing details on
each module function is presented in Appendix A.
A LonWorks version of the module is available, allowing communication over a
LonWorks control network. Through the network, the module can be instructed to
provide on/off and unloading control. In addition, all module inputs including: suction
pressure, discharge pressure, oil pressure, motor temperature, and discharge
temperature are available for data logging and/or as input to another controller.
The module will be available as part of a package including all necessary sensors, wiring
harnesses, and fittings. The remainder of this document provides a comparison of the
old and new protection modules, bill of materials of the LonCEM module packages,
installation instructions, trouble shooting and application notes, and a description of the
sensor inputs and control outputs. Appendix E summarizes the conversion of the sensor
outputs to engineering units, which is helpful when diagnosing sensor and operational
problems.
P O Box 4808
Phone: 800-462-2759
Syracuse, NY 13221
Fax: 315-432-3274
2.0
Bill of Materials
To simplify installation, all of the required parts are included in a single package.
Separate packages were developed for modules with and without the LonWorks
communication option. The following table lists all the components supplied in each
package.
0TA1064
Package
without
LonWorks
(Quantity)
1
2
3
1
1
1
2
3
1
Carlyle P/N
3TA1061
3TA1062
HK05YZ003
HK05YZ002
06TA680007S**
HH79NZ065
DD08SA051
DD08SA052
DD17GA051
Item
1
1
2
3
4
5
Description
LonCEM (with LonWorks Transciever)
LonCEM (without LonWorks Transciever)
Low Pressure Transducer (suction)
High Pressure Transducer (disch and oil)
Harness for Transducers (15 ft lead wire)
Discharge Temperature Thermistor
(5 Kohm)
SAE Discharge Adapter Fitting
(1.3L, 7/16-20 SAE to NPT)
SAE Suction Adapter Fitting
(3.7L, 7/16-20 SAE to NPT)
Cross Fitting (suction and discharge)
P O Box 4808
Phone: 800-462-2759
Syracuse, NY 13221
Fax: 315-432-3274
3.0
Installation Instructions
The following instructions cover mounting the module in the control panel, installing the
sensor inputs on the compressor, and a description of the control outputs. A complete
wiring diagram is contained in Appendix B which covers the control wiring and the wiring
connections to the module.
P O Box 4808
Phone: 800-462-2759
Syracuse, NY 13221
Fax: 315-432-3274
Item 7
suction
Adapter Fitting
Item 3
Disch. Press.
Transducer
(no special marking on
transducer)
(Suction has
Blue Dot on black
base)
Item 8
Cross Fitting
Item 6
Discharge
Adapter Fitting
The same model pressure transducer is used to measure discharge and oil pressure.
Carlyle Compressor Div.
P O Box 4808
Syracuse, NY 13221
Phone: 800-462-2759
Fax: 315-432-3274
Oil Pressure
Figure 2 shows the compressor oil connections.
1. The oil pressure transducer is connected at the bottom of the oil solenoid sight glass
assembly (optional assembly shown in main diagram) or alternatively at the top of
the oil Tee fitting supplied on the compressor (shown in the exploded view to the
upper left of main diagram).
The oil solenoid sight glass assembly shown in Figure 2 is an optional item (P/N
EF12ZZ025), which can be purchased directly from Carlyle. The standard Oil Tee
fitting supplied on the compressor is also shown.
2. One of the compressor schraeder fittings (removed from either suction or discharge
access ports) should be installed at the end of the oil galley for oil pressure field
measurements.
Oil Solenoid/
Sight Glass
Oil Press.
Access Ftg.
Oil Pressure
Transducer
(no special marking on
transducer)
Motor Temperature
A 5 Kohm thermistor is embedded within the motor windings, and is located between S1
and S2 on the compressor electrical terminal plate. Leads should be extended from the
Carlyle Compressor Div.
P O Box 4808
Phone: 800-462-2759
Syracuse, NY 13221
Fax: 315-432-3274
terminal plate to the motor temperature inputs on the LonCEM module. In the event of a
thermistor failure, a spare thermistor is available between S2 and S3.
Sensor Inputs
Suction Pressure Transducer
Discharge Pressure Transducer
Oil Pressure Transducer
Motor Temp Thermistor
Discharge Temp Thermistor
Input Range
Low
High
-13.2 psig 140 psig
-6.6 psig 450 psig
-6.6 psig 450 psig
-32F
312F
-32F
312F
Corresponding
Signal Range
Low
High
0.1 VDC
4.74 VDC
0.4 VDC
4.9 VDC
0.4 VDC
4.9 VDC
88,480 Ohms
195 Ohms
88,480 Ohms
195 Ohms
1CR
Contactor
This terminal supplies power to the compressor contactor coil/relay. The module uses
this output to turn the compressor on or off. Whenever power is supplied to Ccall
(compressor call input), 1CR is closed pulling in the contactor and starting the
compressor. A 20 second time delay between compressor starts is built into the module.
The time delay is active at initial module power-up, or whenever the compressor is called
for before 20 seconds of off-time has elapsed.
2CR
P O Box 4808
Phone: 800-462-2759
Syracuse, NY 13221
Fax: 315-432-3274
Energized whenever the discharge temperature limit is exceeded (see Table 2).
Typically the LiqM and LiqD outputs are wired in parallel with the motor cooling valve.
Thus, the motor cooling valve is energized whenever the motor or discharge
temperature limits are exceeded (see Appendix B for wiring schematic).
Optionally this output could energize a separate liquid injection valve for discharge
temperature control, injecting liquid refrigerant directly into the rotors for discharge
temperature control. Typically, a temperature activated liquid injection valve (strapped to
discharge line) is used for discharge temperature control.
See the Screw Compressor Application Guide for supplemental (in addition to motor
cooling valve) liquid injection requirements.
Discharge Temperature
Motor Temperature
Unloading (Motor)
Injection
On
F (C)
Injection
Off
F (C)
Shutdown
Temp
F (C)
Reset
Temp
F (C)
205 (96)
180 (82)
N/A
190 (88)
165 (74)
N/A
230 (110)
240 (116)
220 (104)
200 (93)
200 (93)
205 (96)
OIL
Energized during compressor operation and is de-energized when it is shut off. The oil
line and economizer line solenoid valves should be connected in parallel to this output
as they are also sequenced on compressor Start/Stop.
It is critical that oil be supplied to the compressor whenever it is running and not supplied
when it is off. Similar concerns exist regarding the flow of refrigerant through the
economizer line. This output insures this functionality.
VI
VI Coil Output
All refrigeration duty 05TR and 06TR screw compressors are supplied with VI control.
The Vi valve (stem located at the 3 oclock position on the outlet casing) controls the
point at which refrigerant exits the rotors. The Vi valve is energized (hi Vi) when the
compression ratio is above 5:1, and de-energized (low-Vi) when the compression ratio
drops below 5:1. The module continuously monitors the operating pressure ratio and
Carlyle Compressor Div.
P O Box 4808
Phone: 800-462-2759
Syracuse, NY 13221
Fax: 315-432-3274
controls the Vi output accordingly. The Vi control effects compressor power only and
has no effect on compressor capacity. It is controlled for optimal compressor efficiency.
The module has a 30 second time delay before controlling the Vi output. This insures
that the compressor starts in the low Vi (solenoid de-energized) setting.
05TA & 06TA air conditioning screw compressors do not have a Vi valve.
ALM Alarm Output
Energized whenever the module enters an alarm state (compressor may or may not be
operating depending on the severity of the alarm). The coded alarm light (amber) on the
module is flashed at the respective rate in order to indicate the compressor alarm. The
flashing is repeated after a short pause. Each of the sensor failure alarms is preceded
by a long dash. A comprehensive explanation of the alarm states, including the
operational criteria and which alarms require a power reset to clear, is presented in
Appendix D.
P O Box 4808
Phone: 800-462-2759
Syracuse, NY 13221
Fax: 315-432-3274
Suction Pressure
Discharge Pressure
Oil Pressure
Motor Temperature
Discharge Temperature
Memory Storage
The following information is stored in the modules permanent memory.
All sensor readings recorded prior to the last compressor alarm
Number of Compressor Cycles
Compressor Run-Time
Cumulative Alarm Trips for each Compressor Alarm
P O Box 4808
Phone: 800-462-2759
10
Syracuse, NY 13221
Fax: 315-432-3274
P O Box 4808
Phone: 800-462-2759
11
Syracuse, NY 13221
Fax: 315-432-3274
Appendix A
- Functional Overview
LonCEM FUNCTIONAL LOGIC
START-UP SEQUENCE
DISCHARGE TEMPERATURE
CONTROL
n
n
n
n
n
VI CONTROL
n The VI coil is energized when the
P O Box 4808
Phone: 800-462-2759
12
Syracuse, NY 13221
Fax: 315-432-3274
Appendix B
Wiring Schematic
Carlyle LonCEM
A 20 Second Time-Delay between Compressor Starts is Built Into the Module
Reset Contacts 4
(Optional)
Rack Controller
HPS/LPS6
Suctio
Suction
Pressure
n
Discharge
Pressure
Oil
Pressure
VSR7
R (+5)
W (sig)
B (gnd)
Slimits
Ccall
240V 120V
L1 2
Com
CR1
R (+5)
W (sig)
B (gnd)
CR2
Liq M
Liq D
R (+5)
W (sig)
B (gnd)
XL Contactor Coil
PW Contactor Coil
Motor Cooling Coil
Unloader Coil3
UN
Motor1
Temp
Oil Solenoid
Oil
Discharge1
Temp
VI
AL
Unused
Econ
Solenoid
Vi Coil
Alarm
Output
LonWorks
Communication
Notes:
1. Connections for Motor Temp, Discharge Temp, and echelon communications are all polarity insensitive.
2. L1 must be jumpered to 240V or 120V depending on line voltage. The drawing shows wiring for 120V. The L1
input is used to power the alarm output.
3. The compressor is loaded when the solenoid is energized and unloaded when de-energized.
4. A normally closed set of contacts can be added to reset power to the module. Useful for remotely resetting a
module out on an Alarm Failure
5. The diagnostic alarm code is flashed by the yellow alarm light during a compressor alarm.
6. The system safeties are monitored on the Slimits Input. This input actually powers the contactor output and is
switched through the module. See section 1.2 for details on the additional required system safeties.
7. A voltage sensing relay (VSR) (or an equivalent method) should be used to detect if power is lost to the line side of
the contactor (i.e. circuit breaker has tripped).
P O Box 4808
Phone: 800-462-2759
13
Syracuse, NY 13221
Fax: 315-432-3274
Additional Notes
1. Each sensor (pressure transducers and thermistors) should be run in separate shielded cables, with the
drain wire wrapped around the ground* wire and both connected to the ground input.
2. The shielded cable drain wire should only be connected at the module end (i.e. not grounded at the sensor
end).
* The ground wire is the black wire for the pressure transducers and is whatever wire is connected to the
ground input (bottom input) for the thermistors.
P O Box 4808
Phone: 800-462-2759
14
Syracuse, NY 13221
Fax: 315-432-3274
ALARM
Reverse Rotation
If at any point between 1.25 and 15 seconds after startup a decrease in the
discharge pressure of over 10 psig is detected, a shutdown sequence 2 is
initiated. Reverse rotation is only checked during the first 15 seconds of
compressor operation.
Yes
No
No
Yes
Yes
No
If the motor temperature rises above 220F, the unloader is de-energized and
this alarm code is flashed until the temperature drops to 205F.
No
No
Pd1 Pd2 > 10 psig, where Pd2 is recorded 1.25 sec after Pd1
Discharge Temperature
If the discharge temperature rises above 230F, a shutdown sequence is
initiated. Once the discharge temperature drops below 200F for 30
continuous seconds the module will automatically reset.
Motor Temperature
All outputs are de-energized (except for alarm) and the appropriate alarm code is flashed.
Carlyle Compressor Div.
P O Box 4808
Syracuse, NY 13221
Phone: 800-462-2759
Fax: 315-432-3274
15
Alarm Manual
Code Reset
ALARM
Sensor Failure
If at any point the module detects a failure of an input device (thermistor,
pressure transducer), the module will initiate a shutdown sequence.
Motor Thermistor Failure
Discharge Thermistor Failure
Suction Pressure Transducer Failure
Oil Pressure Sensor Failure
Discharge Pressure Sensor Failure
1-1
1-2
1-3
1-4
1-5
No
No
No
No
No
DIAGNOSTIC CODES
CODE
Definition
1
Reverse Rotation
2
Safety Circuit Open
3
Change Oil Filter
4
Low Oil Differential
5
High Discharge Temperature
6
High Motor Temperature
7
Compressor Unloading
1-1
Motor Thermistor Failure
1-2
Discharge Thermistor Failure
1-3
Suction Press Sensor Failure
1-4
Oil Pressure Sensor Failure
1-5
Discharge Press Sensor Failure
Notes:
- The alarm code is flashed out by the amber alarm lamp
- A pause is present after each code is flashed out
- The sensor failure codes (1-1:1-5) are preceded by a long
steady lamp to distinguish them from the other alarm codes
P O Box 4808
Phone: 800-462-2759
16
Syracuse, NY 13221
Fax: 315-432-3274
5
4
3
2
1
0
-20
20
40
60
80
100
120
140
Pressure (PSIG)
P S IG = 3 3 . 0 * V o u t - 1 6 . 5
0
-50
50
100
350
400
450
500
P O Box 4808
Phone: 800-462-2759
17
Syracuse, NY 13221
Fax: 315-432-3274
Voltage
(VDC)
4
3.9
3.8
3.7
3.6
3.5
3.4
3.3
3.2
3.1
3
2.9
2.8
2.7
2.6
2.5
2.4
2.3
2.2
Resistance
(ohms)
6480.0
5743.6
5130.0
4610.8
4165.7
3780.0
3442.5
3144.7
2880.0
2643.2
2430.0
2237.1
2061.8
1901.7
1755.0
1620.0
1495.4
1380.0
1272.9
Temp
(C)
19.2
21.9
24.4
26.9
29.2
31.5
33.7
35.9
38.1
40.2
42.3
44.4
46.5
48.6
50.7
52.8
54.9
57.1
59.4
Temp
(F)
66.5
71.4
75.9
80.3
84.6
88.7
92.7
96.6
100.5
104.3
108.1
111.9
115.6
119.4
123.2
127.0
130.9
134.8
138.8
Voltage
(VDC)
2.1
2
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
Resistance
(ohms)
1173.1
1080.0
992.9
911.2
834.5
762.4
694.3
630.0
569.2
511.6
456.9
405.0
355.6
308.6
263.7
220.9
180.0
140.9
103.4
Temp
(C)
61.6
64.0
66.4
68.8
71.4
74.1
76.9
79.9
83.1
86.4
90.1
94.0
98.4
103.3
108.8
115.2
122.9
132.5
145.2
Temp
(F)
142.9
147.1
151.4
155.9
160.6
165.4
170.5
175.8
181.5
187.6
194.1
201.3
209.1
217.9
227.8
239.4
253.2
270.4
293.3
Notes
1. Voltage measured between thermistor input pins on module sensor terminal block.
2. Resistance measured across the Thermistor Leads when not connected to module.
P O Box 4808
Phone: 800-462-2759
18
Syracuse, NY 13221
Fax: 315-432-3274
APPENDIX B
Original Carlyle Electronic Module (CEM)
Table of Contents
Page
1.0 Overview
CEM
Version
AA2203-4
Injection
on
F (C)
Injection
off
F (C)
Time
Delay
Seconds
Shutdown
Temp.
F (C)
Reset
Temp.
F (C)
Reset Time
Delay
Seconds
Discharge
205 (96)
190 (88)
230 (110)
200 (93)
30
Motor
180 (82)
165 (74)
240 (116)
200 (93)
Unloading
(motor)
N/A
N/A
N/A
220 (104
205 (96)
30
N/A
L1
COMMON (L2)
LPS
HPS
OPDS
RRPS
240 OR
115 VOLT
L1
1CR
2CR
ALARM RELAY
DPDT
OPDS POWER
BREAKS ON CEM
FAULT
240 / 120
L2
LIQ
OIL
ALM
UNL
INPUT TO RACK
CONTROLLER
CONTACTOR COIL
RACK CONTROLLER
CONTACTS
1CR
ALM
2CR
LIQ
OIL
The oil line and the economizer line solenoids are
connected in parallel at this output. If no partwind start is used, connect the economizer line
solenoid to the 2CR output. It is critical that oil be
supplied to the compressor whenever it is running
and not supplied when off. This output ensures
that will happen. There is a 2-second time delay
between when 1CR is closed and OIL is closed
UNL
Each 05T and 06T screw compressor is supplied
with 1 step of unloading. The unloader coil and Vi
coil (if using an 05TR or 06TR compressor) are
connected in parallel to this output. If the
application calls for taking advantage of
unloading the compressor, or operating at the low
Vi setting, a rack controller or other controlling
device must be used. Connect the signal from the
rack controller or other controlling device in series
between the CEM output and the unloader or Vi
coil. The CEM has a built-in 45-second time delay
between when 1CR is closed and the UNL output
is closed. This allows the compressor to run for
45 seconds unloaded and with a low Vi on startup which assists in creating a softer start. The
UNL LED will light when the output is closed.
TIME DELAY
The CEM also has a built-in timer which will delay
the start of the compressor anywhere between 0
and 300 seconds from when power is supplied to
L1. This is useful with multiple compressors on a
rack to prevent all compressors from starting at
the same time.
TO CONDENSER
DISCHARGE
LINE
OIL SEP.
LEAD COMPRESSOR
OPDS
FPDS
OIL HEATER
LEVEL SWITCH
3 MICRON FILTERS
E
IL
LI
OIL COOLER
MIXING
VALVE *
OIL SOLENOID
P
OPDS
HAND VALVE
FPDS
FILTER PRESSURE
DIFFERENTIAL SWITCH
PRESSURE
OIL PRESSURE
DIFFERENTIAL SWITCH
SIGHT GLASS
*Note: Other oil temperature control options are available. See section 3.7.
EVAPORATOR
CONDENSER
LEAD COMPRESSOR
RLPS
LPS
OIL SEP.
HPS
LPS
RLPS
HPS
DISCHARGE
RLPS
RLPS
LPS
HPS
LPS
HPS
HPS
HIGH PRESSURE
SWITCH
EXPANSION VALVE
LPS
LOW PRESSURE
SWITCH
SOLENOID
CHECK VALVE
MOTOR COOLING
VALVE
TM